Acids removal and methane conversion process using a supersonic flow reactor

ABSTRACT

Methods and systems are provided for converting methane in a feed stream to acetylene. The method includes removing at least a portion of acids from a hydrocarbon stream. The hydrocarbon stream is introduced into a supersonic reactor and pyrolyzed to convert at least a portion of the methane to acetylene. The reactor effluent stream may be treated to convert acetylene to another hydrocarbon process. The method according to certain aspects includes controlling the level of acids in the hydrocarbon stream by use of adsorbents or basic solutions.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from Provisional Application No.61/691,355 filed Aug. 21, 2012, the contents of which are herebyincorporated by reference.

BACKGROUND OF THE INVENTION

A process is disclosed for removing contaminants from a process streamand converting methane in the process stream to acetylene using asupersonic flow reactor. More particularly, a process is provided forremoval of trace and greater amounts of acids. This process can be usedin conjunction with other contaminant removal processes includingmercury removal, water and carbon dioxide removal, and removal of sulfurcontaining compounds containing these impurities from the processstream.

Light olefin materials, including ethylene and propylene, represent alarge portion of the worldwide demand in the petrochemical industry.Light olefins are used in the production of numerous chemical productsvia polymerization, oligomerization, alkylation and other well-knownchemical reactions. Producing large quantities of light olefin materialin an economical manner, therefore, is a focus in the petrochemicalindustry. These light olefins are essential building blocks for themodern petrochemical and chemical industries. The main source for thesematerials in present day refining is the steam cracking of petroleumfeeds.

The cracking of hydrocarbons brought about by heating a feedstockmaterial in a furnace has long been used to produce useful products,including for example, olefin products. For example, ethylene, which isamong the more important products in the chemical industry, can beproduced by the pyrolysis of feedstocks ranging from light paraffins,such as ethane and propane, to heavier fractions such as naphtha.Typically, the lighter feedstocks produce higher ethylene yields (50-55%for ethane compared to 25-30% for naphtha); however, the cost of thefeedstock is more likely to determine which is used. Historically,naphtha cracking has provided the largest source of ethylene, followedby ethane and propane pyrolysis, cracking, or dehydrogenation. Due tothe large demand for ethylene and other light olefinic materials,however, the cost of these traditional feeds has steadily increased.

Energy consumption is another cost factor impacting the pyrolyticproduction of chemical products from various feedstocks. Over the pastseveral decades, there have been significant improvements in theefficiency of the pyrolysis process that have reduced the costs ofproduction. In a typical or conventional pyrolysis plant, a feedstockpasses through a plurality of heat exchanger tubes where it is heatedexternally to a pyrolysis temperature by the combustion products of fueloil or natural gas and air. One of the more important steps taken tominimize production costs has been the reduction of the residence timefor a feedstock in the heat exchanger tubes of a pyrolysis furnace.Reduction of the residence time increases the yield of the desiredproduct while reducing the production of heavier by-products that tendto foul the pyrolysis tube walls. However, there is little room left toimprove the residence times or overall energy consumption in traditionalpyrolysis processes.

More recent attempts to decrease light olefin production costs includeutilizing alternative processes and/or feed streams. In one approach,hydrocarbon oxygenates and more specifically methanol or dimethylether(DME) are used as an alternative feedstock for producing light olefinproducts. Oxygenates can be produced from available materials such ascoal, natural gas, recycled plastics, various carbon waste streams fromindustry and various products and by-products from the agriculturalindustry. Making methanol and other oxygenates from these types of rawmaterials is well established and typically includes one or moregenerally known processes such as the manufacture of synthesis gas usinga nickel or cobalt catalyst in a steam reforming step followed by amethanol synthesis step at relatively high pressure using a copper-basedcatalyst.

Once the oxygenates are formed, the process includes catalyticallyconverting the oxygenates, such as methanol, into the desired lightolefin products in an oxygenate to olefin (OTO) process. Techniques forconverting oxygenates, such as methanol to light olefins (MTO), aredescribed in U.S. Pat. No. 4,387,263, which discloses a process thatutilizes a catalytic conversion zone containing a zeolitic typecatalyst. U.S. Pat. No. 4,587,373 discloses using a zeolitic catalystlike ZSM-5 for purposes of making light olefins. U.S. Pat. No.5,095,163; U.S. Pat. No. 5,126,308 and U.S. Pat. No. 5,191,141 on theother hand, disclose an MTO conversion technology utilizing anon-zeolitic molecular sieve catalytic material, such as a metalaluminophosphate (ELAPO) molecular sieve. OTO and MTO processes, whileuseful, utilize an indirect process for forming a desired hydrocarbonproduct by first converting a feed to an oxygenate and subsequentlyconverting the oxygenate to the hydrocarbon product. This indirect routeof production is often associated with energy and cost penalties, oftenreducing the advantage gained by using a less expensive feed material.

Recently, attempts have been made to use pyrolysis to convert naturalgas to ethylene. U.S. Pat. No. 7,183,451 discloses heating natural gasto a temperature at which a fraction is converted to hydrogen and ahydrocarbon product such as acetylene or ethylene. The product stream isthen quenched to stop further reaction and subsequently reacted in thepresence of a catalyst to form liquids to be transported. The liquidsultimately produced include naphtha, gasoline, or diesel. While thismethod may be effective for converting a portion of natural gas toacetylene or ethylene, it is estimated that this approach will provideonly about a 40% yield of acetylene from a methane feed stream. While ithas been identified that higher temperatures in conjunction with shortresidence times can increase the yield, technical limitations preventfurther improvement to this process in this regard.

While the foregoing traditional pyrolysis systems provide solutions forconverting ethane and propane into other useful hydrocarbon products,they have proven either ineffective or uneconomical for convertingmethane into these other products, such as, for example ethylene. WhileMTO technology is promising, these processes can be expensive due to theindirect approach of forming the desired product. Due to continuedincreases in the price of feeds for traditional processes, such asethane and naphtha, and the abundant supply and corresponding low costof natural gas and other methane sources available, for example the morerecent accessibility of shale gas, it is desirable to providecommercially feasible and cost effective ways to use methane as a feedfor producing ethylene and other useful hydrocarbons.

In the process of the present invention, it has been found important tominimize the concentration of water as well as carbon monoxide andcarbon dioxide to avoid the occurrence of a water shift reaction whichmay result in undesired products being produced as well as reduce thequantity of the desired acetylene. Other contaminants should be removedfor environmental, production or other reasons including therepeatability of the process. Since variations in the hydrocarbon streambeing processed in accordance with this invention may result in productvariations, it is highly desired to have consistency in the hydrocarbonstream even when it is provided from different sources. Natural gaswells from different regions will produce natural gas of differingcompositions with anywhere from a few percent carbon dioxide up to amajority of the volume being carbon dioxide and the contaminant removalsystem will need to be designed to deal with such differentcompositions.

It has been found that a variety of hydrocarbon containing acids need tobe removed from hydrocarbon streams. These include hydrochloric acid,sulfuric acid, hydrofluoric acid and organic acids, such as acetic acid,naphthenic acid, and other carboxylic acids and formic acid.

SUMMARY OF THE INVENTION

According to one aspect of the invention is provided a method forproducing acetylene. The method generally includes introducing a feedstream portion of a hydrocarbon stream including methane into asupersonic reactor. The method also includes pyrolyzing the methane inthe supersonic reactor to form a reactor effluent stream portion of thehydrocarbon stream including acetylene. The method further includestreating at least a portion of the hydrocarbon stream in a contaminantremoval zone to remove acids such as hydrochloric acid, sulfuric acid,hydrofluoric acid and organic acids, such as acetic acid, naphthenicacid, and other carboxylic acids and formic acid from the processstream.

According to another aspect of the invention a method for controllingcontaminant levels in a hydrocarbon stream in the production ofacetylene from a methane feed stream is provided. The method includesintroducing a feed stream portion of a hydrocarbon stream includingmethane into a supersonic reactor. The method also includes pyrolyzingthe methane in the supersonic reactor to form a reactor effluent streamportion of the hydrocarbon stream including acetylene. The methodfurther includes maintaining the concentration level of acids in atleast a portion of the process stream to below specified levels.

According to yet another aspect of the invention is provided a systemfor producing acetylene from a methane feed stream. The system includesa supersonic reactor for receiving a methane feed stream and configuredto convert at least a portion of methane in the methane feed stream toacetylene through pyrolysis and to emit an effluent stream including theacetylene. The system also includes a hydrocarbon conversion zone incommunication with the supersonic reactor and configured to receive theeffluent stream and convert at least a portion of the acetylene thereinto another hydrocarbon compound in a product stream. The system includesa hydrocarbon stream line for transporting the methane feed stream, thereactor effluent stream, and the product stream. The system furtherincludes a contaminant removal zone in communication with thehydrocarbon stream line for removing acids from the process stream fromone or more of the methane feed stream, the effluent stream, and theproduct stream.

A single adsorbent layer to specifically remove the acids listed ascontaminants here may be used. It is also contemplated that theinvention would include the use of multi-layer adsorbent beds to removeother contaminants. The acids removal layer activated or promotedaluminas, silica gel, activated carbons or zeolites, such as 13X or 5Aor other appropriate adsorbent. The water removal layer can be a varietyof adsorbents, such as zeolite 3A, 4A, or 13X.

BRIEF DESCRIPTION OF THE DRAWING

The FIGURE shows the flow scheme for a process of producing ahydrocarbon product by use of a supersonic reactor with one or morecontaminant removal zones employed in the process.

DETAILED DESCRIPTION

One proposed alternative to the previous methods of producing olefinsthat has not gained much commercial traction includes passing ahydrocarbon feedstock into a supersonic reactor and accelerating it tosupersonic speed to provide kinetic energy that can be transformed intoheat to enable an endothermic pyrolysis reaction to occur. Variations ofthis process are set out in U.S. Pat. No. 4,136,015 and U.S. Pat. No.4,724,272, and SU 392723A. These processes include combusting afeedstock or carrier fluid in an oxygen-rich environment to increase thetemperature of the feed and accelerate the feed to supersonic speeds. Ashock wave is created within the reactor to initiate pyrolysis orcracking of the feed.

More recently, U.S. Pat. No. 5,219,530 and U.S. Pat. No. 5,300,216 havesuggested a similar process that utilizes a shock wave reactor toprovide kinetic energy for initiating pyrolysis of natural gas toproduce acetylene. More particularly, this process includes passingsteam through a heater section to become superheated and accelerated toa nearly supersonic speed. The heated fluid is conveyed to a nozzlewhich acts to expand the carrier fluid to a supersonic speed and lowertemperature. An ethane feedstock is passed through a compressor andheater and injected by nozzles to mix with the supersonic carrier fluidto turbulently mix together at a Mach 2.8 speed and a temperature ofabout 427° C. The temperature in the mixing section remains low enoughto restrict premature pyrolysis. The shockwave reactor includes apyrolysis section with a gradually increasing cross-sectional area wherea standing shock wave is formed by back pressure in the reactor due toflow restriction at the outlet. The shock wave rapidly decreases thespeed of the fluid, correspondingly rapidly increasing the temperatureof the mixture by converting the kinetic energy into heat. Thisimmediately initiates pyrolysis of the ethane feedstock to convert it toother products. A quench heat exchanger then receives the pyrolizedmixture to quench the pyrolysis reaction.

Methods and systems for converting hydrocarbon components in methanefeed streams using a supersonic reactor are generally disclosed. As usedherein, the term “methane feed stream” includes any feed streamcomprising methane. The methane feed streams provided for processing inthe supersonic reactor generally include methane and form at least aportion of a process stream that includes at least one contaminant. Themethods and systems presented herein remove or convert the contaminantin the process stream and convert at least a portion of the methane to adesired product hydrocarbon compound to produce a product stream havinga reduced contaminant level and a higher concentration of the producthydrocarbon compound relative to the feed stream. By one approach, ahydrocarbon stream portion of the process stream includes thecontaminant and methods and systems presented herein remove or convertthe contaminant in the hydrocarbon stream.

The term “hydrocarbon stream” as used herein refers to one or morestreams that provide at least a portion of the methane feed streamentering the supersonic reactor as described herein or are produced fromthe supersonic reactor from the methane feed stream, regardless ofwhether further treatment or processing is conducted on such hydrocarbonstream. The “hydrocarbon stream” may include the methane feed stream, asupersonic reactor effluent stream, a desired product stream exiting adownstream hydrocarbon conversion process or any intermediate orby-product streams formed during the processes described herein. Thehydrocarbon stream may be carried via a process stream. The term“process stream” as used herein includes the “hydrocarbon stream” asdescribed above, as well as it may include a carrier fluid stream, afuel stream, an oxygen source stream, or any streams used in the systemsand the processes described herein.

Prior attempts to convert light paraffin or alkane feed streams,including ethane and propane feed streams, to other hydrocarbons usingsupersonic flow reactors have shown promise in providing higher yieldsof desired products from a particular feed stream than other moretraditional pyrolysis systems. Specifically, the ability of these typesof processes to provide very high reaction temperatures with very shortassociated residence times offers significant improvement overtraditional pyrolysis processes. It has more recently been realized thatthese processes may also be able to convert methane to acetylene andother useful hydrocarbons, whereas more traditional pyrolysis processeswere incapable or inefficient for such conversions.

The majority of previous work with supersonic reactor systems, however,has been theoretical or research based, and thus has not addressedproblems associated with practicing the process on a commercial scale.In addition, many of these prior disclosures do not contemplate usingsupersonic reactors to effectuate pyrolysis of a methane feed stream,and tend to focus primarily on the pyrolysis of ethane and propane. Oneproblem that has recently been identified with adopting the use of asupersonic flow reactor for light alkane pyrolysis, and morespecifically the pyrolysis of methane feeds to form acetylene and otheruseful products therefrom, includes negative effects that particularcontaminants in commercial feed streams can create on these processesand/or the products produced therefrom. Previous work has not consideredcontaminants and the need to control or remove specific contaminants,especially in light of potential downstream processing of the reactoreffluent stream.

The term “adsorption” as used herein encompasses the use of a solidsupport to remove atoms, ions or molecules from a gas or liquid. Theadsorption may be by “physisorption” in which the adsorption involvessurface attractions or “chemisorptions” where there are actual chemicalchanges in the contaminant that is being removed. Depending upon theparticular adsorbent, contaminant and stream being purified, theadsorption process may be regenerative or nonregenerative. Eitherpressure swing adsorption, temperature swing adsorption or displacementprocesses may be employed in regenerative processes. A combination ofthese processes may also be used. The adsorbents may be any porousmaterial known to have application as an adsorbent including carbonmaterials such as activated carbon clays, molecular sieves includingzeolites and metal organic frameworks (MOFs), metal oxides includingsilica gel and aluminas that are promoted or activated, as well as otherporous materials that can be used to remove or separate contaminants.

“Pressure swing adsorption (PSA)” refers to a process where acontaminant is adsorbed from a gas when the process is under arelatively higher pressure and then the contaminant is removed ordesorbed thus regenerating the adsorbent at a lower pressure.

“Temperature swing adsorption (TSA)” refers to a process whereregeneration of the adsorbent is achieved by an increase in temperaturesuch as by sending a heated gas through the adsorbent bed to remove ordesorb the contaminant. Then the adsorbent bed is often cooled beforeresumption of the adsorption of the contaminant.

“Displacement” refers to a process where the regeneration of theadsorbent is achieved by desorbing the contaminant with another liquidthat takes its place on the adsorbent. Such as process is shown in U.S.Pat. No. 8,211,312 in which a feed and a desorbent are applied atdifferent locations along an adsorbent bed along with withdrawals of anextract and a raffinate. The adsorbent bed functions as a simulatedmoving bed. A circulating adsorbent chamber fluid can simulate a movingbed by changing the composition of the liquid surrounding the adsorbent.Changing the liquid can cause different chemical species to be adsorbedon, and desorbed from, the adsorbent. As an example, initially applyingthe feed to the adsorbent can result in the desired compound or extractto be adsorbed on the adsorbent, and subsequently applying the desorbentcan result in the extract being desorbed and the desorbent beingadsorbed. In such a manner, various materials may be extracted from afeed. In some embodiments of the present invention, a displacementprocess may be employed.

In accordance with various embodiments disclosed herein, therefore,processes and systems for removing or converting contaminants in methanefeed streams are presented. The removal of particular contaminantsand/or the conversion of contaminants into less deleterious compoundshas been identified to improve the overall process for the pyrolysis oflight alkane feeds, including methane feeds, to acetylene and otheruseful products. In some instances, removing these compounds from thehydrocarbon or process stream has been identified to improve theperformance and functioning of the supersonic flow reactor and otherequipment and processes within the system. Removing these contaminantsfrom hydrocarbon or process streams has also been found to reducepoisoning of downstream catalysts and adsorbents used in the process toconvert acetylene produced by the supersonic reactor into other usefulhydrocarbons, for example hydrogenation catalysts that may be used toconvert acetylene into ethylene. Still further, removing certaincontaminants from a hydrocarbon or process stream as set forth hereinmay facilitate meeting product specifications.

In accordance with one approach, the processes and systems disclosedherein are used to treat a hydrocarbon process stream, to remove one ormore contaminants therefrom and convert at least a portion of methane toacetylene. The hydrocarbon process stream described herein includes themethane feed stream provided to the system, which includes methane andmay also include ethane or propane. The methane feed stream may alsoinclude combinations of methane, ethane, and propane at variousconcentrations and may also include other hydrocarbon compounds. In oneapproach, the hydrocarbon feed stream includes natural gas. The naturalgas may be provided from a variety of sources including, but not limitedto, gas fields, oil fields, coal fields, fracking of shale fields,biomass, and landfill gas. In another approach, the methane feed streamcan include a stream from another portion of a refinery or processingplant. For example, light alkanes, including methane, are oftenseparated during processing of crude oil into various products and amethane feed stream may be provided from one of these sources. Thesestreams may be provided from the same refinery or different refinery orfrom a refinery off gas. The methane feed stream may include a streamfrom combinations of different sources as well.

In accordance with the processes and systems described herein, a methanefeed stream may be provided from a remote location or at the location orlocations of the systems and methods described herein. For example,while the methane feed stream source may be located at the same refineryor processing plant where the processes and systems are carried out,such as from production from another on-site hydrocarbon conversionprocess or a local natural gas field, the methane feed stream may beprovided from a remote source via pipelines or other transportationmethods. For example a feed stream may be provided from a remotehydrocarbon processing plant or refinery or a remote natural gas field,and provided as a feed to the systems and processes described herein.Initial processing of a methane stream may occur at the remote source toremove certain contaminants from the methane feed stream. Where suchinitial processing occurs, it may be considered part of the systems andprocesses described herein, or it may occur upstream of the systems andprocesses described herein. Thus, the methane feed stream provided forthe systems and processes described herein may have varying levels ofcontaminants depending on whether initial processing occurs upstreamthereof.

In one example, the methane feed stream has a methane content rangingfrom about 50 to about 100 mol-%. In another example, the concentrationof methane in the hydrocarbon feed ranges from about 70 to about 100mol-% of the hydrocarbon feed. In yet another example, the concentrationof methane ranges from about 90 to about 100 mol-% of the hydrocarbonfeed.

In one example, the concentration of ethane in the methane feed rangesfrom about 0 to about 30 mol-% and in another example from about 0 toabout 10 mol-%. In one example, the concentration of propane in themethane feed ranges from about 0 to about 10 mol-% and in anotherexample from about 0 to about 2 mol-%. The methane feed stream may alsoinclude heavy hydrocarbons, such as aromatics, paraffinic, olefinic, andnaphthenic hydrocarbons. These heavy hydrocarbons if present will likelybe present at concentrations of between about 0 mol-% and about 100mol-%. In another example, they may be present at concentrations ofbetween about 0 mol-% and 10 mol-% and may be present at between about 0mol-% and 2 mol-%.

The present invention relates to the removal of acids from a hydrocarbonfeedstock, preferably with activated or promoted aluminas, metal oxidesor carbonates or type 13X zeolite if the contaminat is present in tracelevels upto a few 100 ppm(v). At higher acid concentrations a basicsolvent such as sodium hydroxide may be used. Certain zeolite/aluminahybrid adsorbents may also be used. The zeolites that can be used mayinclude faujasites (13X, CaX, NaY, CaY, ZnX), chabazites,clinoptilolites and LTA (4A, 5A) zeolites. Other adsorbents may be usedincluding silica gels and activated carbons.

In one embodiment, a water or a caustic wash may precede an acid removaladsorbent bed. This is applicable in situations where greater than tracelevels of acids are to be removed. The water or caustic wash is employedto attain bulk removal while the adsorption bed is used for traceremoval of the acids. The process includes a water wash of reactoreffluent from quench zone in zone 20 (quench or wash tower). Zone 28 or30 may also include an acid removal step as needed to remove acidsformed in the hydrocarbon conversion zone. A neutralizing agent (i.e.caustic) may be added to water circulated to the wash tower.

At very low levels (<10 ppm (v)), the acids are not expected toadversely affect the supersonic reactor metallurgy or yields. However,at higher concentration, the combined effect of steam and acids mayresult in corrosion of the reactor metallurgy. In this case, an acidremoval process needs to be implemented upstream of the supersonicreactor. The presence of polar compounds, water and dissociated oxygenin the reactor is likely to lead to the formation of some acids in thepyrolysis reactor. These acids need be removed downstream of thesupersonic reactor to eliminate potential for fouling and corrosion indownstream processes and heat exchangers. Whether it is advantageous tohave a single or two different acid removal systems (upstream anddownstream) depends on the economics of corrosion/fouling versus cost ofremoval.

In one embodiment, the hydrocarbon feedstock is purified by passagethrough a multi-layer bed for removal of more than one type ofcontaminant.

Another type of adsorbent layer for acid removal that is effective inthe practice of the present invention is an activated or promotedalumina. The promoter is selected from one or more alkali metals oralkaline earth metals. The preferred alkali metals include sodium andpotassium and the preferred alkaline earth metals include magnesium andcalcium.

By one aspect, the hydrocarbon stream includes one or more contaminantsincluding or more type of acids and compounds containing acids. Whilethe systems and processes are described generally herein with regard toremoving these contaminants from a hydrocarbon stream, it should beunderstood that these contaminants may also be removed from otherportions of the process stream.

According to one aspect, the contaminants in the hydrocarbon stream maybe naturally occurring in the feed stream, such as, for example, presentin a natural gas source or added to the feed stream in the process ofextracting the natural gas. According to another aspect, thecontaminants may be added to the hydrocarbon stream during a particularprocess step. In accordance with another aspect, the contaminant may beformed as a result of a specific step in the process, such as a productor by-product of a particular reaction, such as oxygen or carbon dioxidereacting with a hydrocarbon to form an oxygenate.

The process for forming acetylene from the methane feed stream describedherein utilizes a supersonic flow reactor for pyrolyzing methane in thefeed stream to form acetylene. The supersonic flow reactor may includeone or more reactors capable of creating a supersonic flow of a carrierfluid and the methane feed stream and expanding the carrier fluid toinitiate the pyrolysis reaction. In one approach, the process mayinclude a supersonic reactor as generally described in U.S. Pat. No.4,724,272, which is incorporated herein by reference, in their entirety.In another approach, the process and system may include a supersonicreactor such as described as a “shock wave” reactor in U.S. Pat. No.5,219,530 and U.S. Pat. No. 5,300,216, which are incorporated herein byreference, in their entirety. In yet another approach, the supersonicreactor described as a “shock wave” reactor may include a reactor suchas described in “Supersonic Injection and Mixing in the Shock WaveReactor” Robert G. Cerff, University of Washington Graduate School,2010.

In an embodiment of the invention, the feed stream 2 is heated prior tobeing injected into the supersonic reactor. Depending upon the design ofthe supersonic reactor, the methane feed stream may be heated to atemperature greater than about 200° C. The methane feed stream may beheated to a temperature between about 200 to 1500° C. or between 500 to1000° C.

While a variety of supersonic reactors may be used in the presentprocess, an exemplary reactor will have a supersonic reactor thatincludes a reactor vessel generally defining a reactor chamber. Whilethe reactor will often be found as a single reactor, it should beunderstood that it may be formed modularly or as separate vessels. Acombustion zone or chamber is provided for combusting a fuel to producea carrier fluid with the desired temperature and flowrate. The reactormay optionally include a carrier fluid inlet for introducing asupplemental carrier fluid into the reactor. One or more fuel injectorsare provided for injecting a combustible fuel, for example hydrogen,into the combustion chamber. The same or other injectors may be providedfor injecting an oxygen source into the combustion chamber to facilitatecombustion of the fuel. The fuel and oxygen are combusted to produce ahot carrier fluid stream typically having a temperature of from about1200° to about 3500° C. in one example, between about 2000° and about3500° C. in another example, and between about 2500° and 3200° C. in yetanother example. According to one example the carrier fluid stream has apressure of about 1 atm or higher, greater than about 2 atm in anotherexample, and greater than about 4 atm in another example.

The hot carrier fluid stream from the combustion zone is passed througha converging-diverging nozzle to accelerate the flowrate of the carrierfluid to above about Mach 1.0 in one example, between about Mach 1.0 andMach 4.0 in another example, and between about Mach 1.5 and Mach 3.5 inanother example. In this regard, the residence time of the fluid in thereactor portion of the supersonic flow reactor is between about 0.5 and100 ms in one example, about 1.0 and 50 ms in another example, and about1.5 and 20 ms in another example.

A feedstock inlet is provided for injecting the methane feed stream intothe reactor to mix with the carrier fluid. The feedstock inlet mayinclude one or more injectors for injecting the feedstock into thenozzle, a mixing zone, an expansion zone, or a reaction zone or achamber. The injector may include a manifold, including for example aplurality of injection ports.

In one approach, the reactor may include a mixing zone for mixing of thecarrier fluid and the feed stream. In another approach, no mixing zoneis provided, and mixing may occur in the nozzle, expansion zone, orreaction zone of the reactor. An expansion zone includes a divergingwall to produce a rapid reduction in the velocity of the gases flowingtherethrough, to convert the kinetic energy of the flowing fluid tothermal energy to further heat the stream to cause pyrolysis of themethane in the feed, which may occur in the expansion section and/or adownstream reaction section of the reactor. The fluid is quicklyquenched in a quench zone to stop the pyrolysis reaction from furtherconversion of the desired acetylene product to other compounds. Spraybars may be used to introduce a quenching fluid, for example water orsteam into the quench zone.

The reactor effluent exits the reactor via the outlet and as mentionedabove forms a portion of the hydrocarbon stream. The effluent willinclude a larger concentration of acetylene than the feed stream and areduced concentration of methane relative to the feed stream. Thereactor effluent stream may also be referred to herein as an acetylenestream as it includes an increased concentration of acetylene. Theacetylene may be an intermediate stream in a process to form anotherhydrocarbon product or it may be further processed and captured as anacetylene product stream. In one example, the reactor effluent streamhas an acetylene concentration prior to the addition of quenching fluidranging from about 4 to about 60 mol-%. In another example, theconcentration of acetylene ranges from about 10 to about 50 mol-% andfrom about 15 to about 47 mol-% in another example.

In one example, the reactor effluent stream has a reduced methanecontent relative to the methane feed stream ranging from about 10 toabout 90 mol-%. In another example, the concentration of methane rangesfrom about 30 to about 85 mol-% and from about 40 to about 80 mol-% inanother example.

In one example the yield of acetylene produced from methane in the feedin the supersonic reactor is between about 40 and about 95 mol-%. Inanother example, the yield of acetylene produced from methane in thefeed stream is between about 50 and about 90 mol-%. Advantageously, thisprovides a better yield than the estimated 40% yield achieved fromprevious, more traditional, pyrolysis approaches.

By one approach, the reactor effluent stream is reacted to form anotherhydrocarbon compound. In this regard, the reactor effluent portion ofthe hydrocarbon stream may be passed from the reactor outlet to adownstream hydrocarbon conversion process for further processing of thestream. While it should be understood that the reactor effluent streammay undergo several intermediate process steps, such as, for example,water removal, adsorption, and/or absorption to provide a concentratedacetylene stream, these intermediate steps will not be described indetail herein except where particularly relevant to the presentinvention.

The reactor effluent stream having a higher concentration of acetylenemay be passed to a downstream hydrocarbon conversion zone where theacetylene may be converted to form another hydrocarbon product. Thehydrocarbon conversion zone may include a hydrocarbon conversion reactorfor converting the acetylene to another hydrocarbon product. While inone embodiment the invention involves a process for converting at leasta portion of the acetylene in the effluent stream to ethylene throughhydrogenation in a hydrogenation reactor, it should be understood thatthe hydrocarbon conversion zone may include a variety of otherhydrocarbon conversion processes instead of or in addition to ahydrogenation reactor, or a combination of hydrocarbon conversionprocesses. Similarly the process and equipment as discussed herein maybe modified or removed and not intended to be limiting of the processesand systems described herein. Specifically, it has been identified thatseveral other hydrocarbon conversion processes, other than thosedisclosed in previous approaches, may be positioned downstream of thesupersonic reactor, including processes to convert the acetylene intoother hydrocarbons, including, but not limited to: alkenes, alkanes,methane, acrolein, acrylic acid, acrylates, acrylamide, aldehydes,polyacetylides, benzene, toluene, styrene, aniline, cyclohexanone,caprolactam, propylene, butadiene, butyne diol, butandiol, C₂-C₄hydrocarbon compounds, ethylene glycol, diesel fuel, diacids, diols,pyrrolidines, and pyrrolidones.

A contaminant removal zone for removing one or more contaminants fromthe hydrocarbon or process stream may be located at various positionsalong the hydrocarbon or process stream depending on the impact of theparticular contaminant on the product or process and the reason for thecontaminants removal, as described further below. For example,particular contaminants have been identified to interfere with theoperation of the supersonic flow reactor and/or to foul components inthe supersonic flow reactor. Thus, according to one approach, acontaminant removal zone is positioned upstream of the supersonic flowreactor in order to remove these contaminants from the methane feedstream prior to introducing the stream into the supersonic reactor.Other contaminants have been identified to interfere with a downstreamprocessing step or hydrocarbon conversion process, in which case thecontaminant removal zone may be positioned upstream of the supersonicreactor or between the supersonic reactor and the particular downstreamprocessing step at issue. Still other contaminants have been identifiedthat should be removed to meet particular product specifications. Whereit is desired to remove multiple contaminants from the hydrocarbon orprocess stream, various contaminant removal zones may be positioned atdifferent locations along the hydrocarbon or process stream. In stillother approaches, a contaminant removal zone may overlap or beintegrated with another process within the system, in which case thecontaminant may be removed during another portion of the process,including, but not limited to the supersonic reactor or the downstreamhydrocarbon conversion zone. This may be accomplished with or withoutmodification to these particular zones, reactors or processes. While thecontaminant removal zone is often positioned downstream of thehydrocarbon conversion reactor, it should be understood that thecontaminant removal zone in accordance herewith may be positionedupstream of the supersonic flow reactor, between the supersonic flowreactor and the hydrocarbon conversion zone, or downstream of thehydrocarbon conversion zone or along other streams within the processstream, such as, for example, a carrier fluid stream, a fuel stream, anoxygen source stream, or any streams used in the systems and theprocesses described herein.

In one approach, a method includes removing a portion of contaminantsfrom the hydrocarbon stream. In this regard, the hydrocarbon stream maybe passed to the contaminant removal zone. In one approach, the methodincludes controlling the contaminant concentration in the hydrocarbonstream. The contaminant concentration may be controlled by maintainingthe concentration of contaminant in the hydrocarbon stream to below alevel that is tolerable to the supersonic reactor or a downstreamhydrocarbon conversion process. In one approach, the contaminantconcentration is controlled by removing at least a portion of thecontaminant from the hydrocarbon stream. As used herein, the termremoving may refer to actual removal, for example by adsorption,absorption, or membrane separation, or it may refer to conversion of thecontaminant to a more tolerable compound, or both. In one example, thecontaminant concentration is controlled to maintain the level ofcontaminant in the hydrocarbon stream to below a harmful level. Inanother example, the contaminant concentration is controlled to maintainthe level of contaminant in the hydrocarbon stream to below a lowerlevel. In yet another example, the contaminant concentration iscontrolled to maintain the level of contaminant in the hydrocarbonstream to below an even lower level.

The FIGURE provides a flow scheme for an embodiment of the invention. Inthe FIGURE, a hydrocarbon feed 2, such as methane, is shown entering afirst contaminant removal zone 4, then passing through line 6 to one ormore heaters 8. A heated hydrocarbon feed 10 then enters a supersonicreactor 16 together with fuel 12, oxidizer 14 and optional steam 18. Inthe supersonic reactor, a product stream containing acetylene isproduced. The product stream 19 from supersonic reactor 16 may then goto a second contaminant removal zone 20, through line 21 to acompression and adsorption/separation zone 22. If further purificationis necessary, the stream passes through line 23 into a third contaminantremoval zone 24. A purified acetylene stream 25 is sent to hydrocarbonconversion zone 26 to be converted into one or more hydrocarbon productswhich contain one or more impurities. These one or more hydrocarbonproducts 27 are shown being sent to a separation zone 28, then throughline 29 to fourth contaminant removal zone 30, then through line 31 to apolishing reactor 32 to convert unreacted acetylene to the one or morehydrocarbon products. The now purified product stream 33 is sent to aproduct separation zone 34 and the primary product stream 36 is shownexiting at the bottom. Secondary products may also be produced. Whilethere is a single contaminant removal zone shown in four locations inthe FIGURE, each single contaminant removal zone may comprise one ormore separate beds or other contaminant removal apparatus. In someembodiments of the invention, there may be fewer contaminant removalzones depending upon the quality of the hydrocarbon feed 2, productstream 19 and primary product stream 36.

While there have been illustrated and described particular embodimentsand aspects, it will be appreciated that numerous changes andmodifications will occur to those skilled in the art, and it is intendedin the appended claims to cover all those changes and modificationswhich fall within the true spirit and scope of the present disclosureand appended claims.

1. A method for producing acetylene comprising: introducing a feedstream portion of a hydrocarbon stream comprising methane into asupersonic reactor; pyrolyzing the methane in the supersonic reactor toform a reactor effluent stream portion of the hydrocarbon streamcomprising acetylene; and treating at least a portion of the hydrocarbonstream in a contaminant removal zone to remove acids from thehydrocarbon stream
 2. The method of claim 1 wherein said contaminantremoval zone comprises an adsorbent bed wherein said hydrocarbon streamis contacted with an adsorbent material comprising one or moreadsorbents to remove said acids.
 3. The method of claim 1 wherein saidcontaminant removal zone comprises water or a basic solution thatcontacts said hydrocarbon stream to remove said acids.
 4. The method ofclaim 1 wherein pyrolyzing the methane includes accelerating thehydrocarbon stream to a velocity of between about Mach 1.0 and aboutMach 4.0 slowing down the hydrocarbon stream to increase the temperatureof the hydrocarbon process stream.
 5. The method of claim 1 whereinpyrolyzing the methane includes heating the methane to a temperature ofbetween about 1200° and about 3500° C. for a residence time of betweenabout 0.5 and about 100 ms.
 6. The method of claim 1 further comprisingtreating said at least a portion of the hydrocarbon stream to removeother contaminants.
 7. The method of claim 2 wherein said adsorbent is azeolite is selected from the group consisting of faujasites (13X, CaX,NaY, CaY, and ZnX), chabazites, clinoptilolites and LTA (4A, 5A)zeolites.
 8. The method of claim 2 wherein said adsorbent is a silicagel or an activated carbon.
 9. The method of claim 1 wherein the acid isselected from the group consisting of hydrochloric acid, sulfuric acid,hydrofluoric acid, and organic acids.
 10. The method of claim 9 whereinsaid organic acid is selected from the group consisting of acetic acid,formic acid, naphthenic acid and other carboxylic acids.
 11. The methodof claim 3 wherein the basic solution is sodium hydroxide.
 12. Themethod of claim 1 wherein the contaminant removal zone is positionedupstream of the supersonic reactor to remove the portion of the acidsfrom the hydrocarbon stream prior to introducing the process stream intothe supersonic reactor.
 13. The method of claim 1 further comprisingpassing the reactor effluent stream to a downstream hydrocarbonconversion zone and converting at least a portion of the acetylene inthe reactor effluent stream to another hydrocarbon in the hydrocarbonconversion zone.
 14. The method of claim 13 wherein the contaminantremoval zone is positioned downstream of the supersonic reactor andupstream of the hydrocarbon conversion zone to remove the at least aportion of the acids from the hydrocarbon stream prior to introducingthe effluent stream portion thereof into hydrocarbon conversion zone.15. The method of claim 1 wherein said adsorbent is an activated orpromoted alumina wherein a promoter in said promoted alumina is analkali metal or an alkali earth metal.
 16. The method of claim 15wherein said alkali metal is selected from the group consisting oflithium, sodium, potassium and said alkaline earth metals are selectedfrom the group consisting of beryllium, magnesium and calcium.
 17. Amethod for controlling a contaminant level in a process stream in theproduction of acetylene from a methane feed stream, the methodcomprising: introducing a feed stream portion of a hydrocarbon streamcomprising methane into a supersonic reactor; pyrolyzing the methane inthe supersonic reactor to form a reactor effluent stream portion of thehydrocarbon stream comprising acetylene; and maintaining theconcentration of acids in the hydrocarbon stream.
 18. The method ofclaim 17 further comprising passing the reactor effluent stream to ahydrocarbon conversion process for converting at least a portion of theacetylene therein to another hydrocarbon compound.
 19. A system forproducing acetylene from a methane feed stream comprising: a supersonicreactor for receiving a methane feed stream and configured to convert atleast a portion of methane in the methane feed stream to acetylenethrough pyrolysis and to emit an effluent stream including theacetylene; a hydrocarbon conversion zone in communication with thesupersonic reactor and configured to receive the effluent stream andconvert at least a portion of the acetylene therein to anotherhydrocarbon compound in a product stream; a hydrocarbon stream line fortransporting the methane feed stream, the reactor effluent stream, andthe product stream; and a contaminant removal zone in communication withthe hydrocarbon stream line for removing acids from one of the methanefeed stream, the effluent stream, and the product stream.
 20. A methodfor producing acetylene comprising: introducing a feed stream comprisingmethane into a supersonic reactor; pyrolyzing the methane in thesupersonic reactor to form a reactor effluent stream comprisingacetylene; and treating at least a portion of a process stream in acontaminant removal zone to remove acids from the process stream.